Contain
Stop safely, identify affected packs and preserve the product and settings.
Technical guide
Auger filler troubleshooting guide.
A practical diagnostic sequence for powder-feed instability, weight variation, bridging, dust escape, pack contamination and line stoppages.
Weight driftBridgingDust escapePack handling
Start with evidence
Separate a dosing problem from a feeding, pack or measurement problem.
An auger filler can only repeat when the product is presented consistently, the correct tooling is fitted, the pack is positioned correctly and the check scale is used consistently. Record the sequence before changing several settings at once.
- Product batch, loose and settled bulk density
- Auger, tube, outlet and recipe identity
- Hopper level and time since refill
- Pack opening, support and fill height
- Scale, tare method and result sequence
Diagnostic rule
Change one variable, run enough fills to reach a stable condition and keep the rejected results in the record.
Problem matrix
Common symptoms, likely causes and controlled checks.
| Symptom | Possible causes | Checks before adjustment | Next action |
|---|---|---|---|
| Fill weights drift over the run | Density change, hopper-level change, aeration, inconsistent refill, tooling wear or scale method. | Plot fills in sequence and mark start-up, refill, pause and operator changes. | Stabilise powder presentation; verify scale and tooling; recalibrate under the production condition. |
| Intermittent low fills | Bridging, rat-holing, outlet blockage, incomplete screw charging or pack triggering. | Observe the hopper and outlet during the low result; inspect residue and sensor state. | Review agitation, refill level, screw geometry, outlet and sensor position using the actual powder. |
| Intermittent high fills | Flooding after a stop, free fall after auger stop, static release or excessive fine-fill speed. | Compare steady fills with first fill after stop and remove/restart events. | Review outlet geometry, cut-off profile, delay and restart logic; do not hide the event by averaging. |
| Powder bridges in the hopper | Cohesive product, unsuitable wall angle, low agitation, compaction or refill method. | Record where the bridge forms and whether gentle agitation restores flow. | Trial product-matched agitation, level control, hopper presentation and screw feeder options. |
| Dust escapes around the pack | Excessive drop height, poor nozzle fit, displaced air, high feed velocity or inadequate capture. | Observe the source and check rim, thread or seal-area contamination. | Reduce fall height where practical; review nozzle, shroud, extraction and settling time. |
| Pack misses or spills | Opening too small, soft pouch not supported, bottle instability or incorrect fill height. | Use production samples at dimensional limits and video the operator or indexing cycle. | Change pack support, clamp, guides, nozzle profile or presentation method. |
| Good start-up, poor restart | Settling or flooding during pause, product compaction, stale material at outlet or recipe sequence. | Include controlled short and long pauses in the trial. | Define restart checks and purge/prime sequence; confirm settings under realistic stops. |
Six-step method
Troubleshoot without losing the original condition.
Verify measurement
Check tare, scale resolution, calibration status and sampling method.
Inspect product feed
Look for bridging, rat-holing, aeration, compaction, inconsistent level or refill events.
Inspect tooling
Confirm screw, tube, nozzle, seals, wear and assembly against the approved recipe.
Run one change
Adjust one parameter or component and record consecutive results.
Confirm recovery
Repeat start, stable run, refill and restart before releasing the process.
When the powder needs a new trial.
A new supplier, formulation, moisture condition or particle distribution can change bulk density and flow. Treat the material as a new application if the previous settings no longer reproduce the approved feed condition.
Use the sample trial and FAT guide.
When the problem belongs to another machine.
If fill weights are stable but seals fail, caps misapply or labels move, isolate the downstream process rather than changing the auger recipe. Review the whole sequence on the complete auger filling line page.
Technical support
Send troubleshooting evidenceSend the result sequence, not only the average.
Include photographs or video, product batch, tooling ID, settings, hopper events and consecutive fill results so Lancing can separate the likely causes.